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CHROME 1.25 INCH (31.75 MM) DIAMETER HANDLEBAR KIT
J044052008-09-04
GENERAL
Kit Number
56032-08
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
This kit does not fit models equipped with a hydraulic clutch, handlebar mounted gauges or the Road Tech® Radio.
Additional Parts or Accessories Required
Separate purchase of additional parts or accessories is required for proper installation of this Handlebar Kit on this model motorcycle. Please see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for this model.
For Australia, Brazil, England, Europe and Japan, two special screws (Part Number 2935A) will also be required.
Tools and Supplies Required
Loctite® 271 Threadlocker and Sealant - Red (H-D Part Number 99671-97) is required for the proper installation of this kit.
Fresh, uncontaminated DOT 4 brake fluid from a sealed container will also be needed.
WARNING
Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a)
For models that retain the original brake line, the two brake-line gaskets found at each banjo fitting must be replaced. Refer to the appropriate parts catalog or see a Harley-Davidson dealer for the correct part numbers.
Motorcycles equipped with a glued left-side hand grip will also require a new grip, sold separately. Refer to the parts catalog for replacement stock hand grips.
Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory hand grips that are available.
WARNING
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
NOTE
This instruction sheet references service manual information. A service manual for this year and model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Kit Contents
See Figure 6 and Table 1.
INSTALLATION
Preparation
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNING
Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
  1. Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. Retain all seat mounting hardware.
WARNING
Contact with DOT 4 brake fluid can have serious health effects. Failure to wear proper skin and eye protection could result in death or serious injury.
  • If inhaled: Keep calm, remove to fresh air, seek medical attention.
  • If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
  • If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
  • If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Contact Poison Control. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240e)
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c)
NOTE
Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills).
Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spillage or splash of DOT 4 brake fluid.
  1. Drain the brake fluid from the front brake reservoir and lines per the instructions in the service manual.
Original Handlebar Removal
NOTE
Cover the front fender and the fuel tank with H-D Service Covers or clean shop towels to prevent scratching the finish.
NOTICE
Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)
  1. Using a T-40 TORX® drive head, remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee.
  2. Carefully make note of the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See the service manual.
  3. Remove the front brake line assembly from the motorcycle.
  4. Using a T27 TORX® drive head, remove the front-brake master cylinder and clutch-lever assemblies from the handlebar.
    5. NOTE
    Refer to the parts catalog for the correct year and model for a replacement stock clutch cable, if needed.
    Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory Custom Braided Clutch Cables and Brake Lines that are available.
  5. Refer to the service manual, and follow the instructions to disconnect the clutch cable from the clutch lever. If the clutch cable is being replaced, follow the instructions to disconnect the clutch cable from the side cover, and remove the cable from the vehicle.
  6. Remove the headlamp assembly from the headlamp nacelle. See the service manual.
  7. Refer to the MOLEX ELECTRICAL CONNECTORS section of the service manual. Disconnect the handlebar control wiring from the gray eight-way and black six-way main harness connectors inside the headlamp nacelle. Disconnect the electronic cruise-control wiring from the two three-way connectors if the vehicle is so equipped.
  8. Refer to the service manual for removal of the right-side switch housing assembly and harness, and removal of the left-side switch housing assembly and wire harness.
  9. If the plastic wiring retainer clips that secured both switch harnesses to the handlebar are still attached to the harnesses or handlebar, remove and discard them.
  10. If the left-side hand grip is not glued to the handlebar: Remove the end cap from the grip if so equipped. Remove the hand grip and set it aside for installation onto the new handlebar.
  11. Remove the end cap from the existing right handlebar grip if so equipped. Remove the grip from the handlebar.
NOTE
The twist grip sensor in the right side of the handlebar has a seal cap that protects internal electrodes from dirt and moisture, and also serves as a retention device for the throttle grip.
To remove the grip, a slight tug may be necessary to release the index pins in the grip from the receptacle in the seal cap.
If the throttle grip IS being replaced: Discard the throttle grip and proceed to step 12.
If the throttle grip IS NOT being replaced: Upon removing the grip, note if the seal cap is attached to the end of the twist grip sensor.
  • If the seal cap is attached to the sensor, proceed to step 12.
  • If the seal cap is still fastened to the index pins inside the throttle grip, use a stiff piece of mechanics' wire to lasso the seal cap and pull it free of the index pins.
The original equipment (OE) twist grip sensor MUST be replaced with a new sensor. If carefully removed, the OE sensor can be saved for possible re-use at a later time.
1. Refer to the service manual, and follow the instructions for this model motorcycle to remove the OE twist grip sensor.
a. Access the six-way twist grip sensor jumper harness connector [204] inside the vehicle, and disconnect the black Molex connector halves.
b. Gently pull the twist grip sensor and wires out of the handlebar until the small green connector pair is exposed.
c. Note: the external latch on the small green twist grip sensor connector inside the handlebar will break if the twist grip sensor is pulled too hard. A broken latch will prevent positive engagement of the pin and socket housings. Since the pin and socket housings are not serviceable, any damage will render the OE twist grip sensor unusable. Disconnect the green socket housing on the sensor from the green pin housing on the jumper harness inside the handlebar by carefully prying up the latch with a small, flat screwdriver or similar tool.
d. Remove the twist grip sensor from the vehicle and set aside for possible later use.
e. Pull the jumper harness out through the lower center wire exit slot in the handlebar and set aside for possible later use.
1Headlamp
2Handlebar cover
3Handlebar cover insert
4Fork lock plate
5Nacelle (left half)
6Nacelle trim strip
7Nut
8Flat head screw (2)
9Pan head screw
10Flat washer
11Nut with washer
Figure 1. Nacelle, Headlamp and Handlebar Cover (FLHR Models)
2. See Figure 1. Reaching inside the headlamp nacelle (5), remove the flange nut (7) to release the trim strip (6) at the top of the nacelle. Retain the nut and trim strip for later assembly.
3. Carefully pry off the fork-lock label plate (4) from the OE handlebar cover (2). Remove the entire plastic plate; do not remove the adhesive label from the plate.
4. For North America: Remove and retain the two Phillips flat head screws (8) underneath the label plate that hold the handlebar cover to the fork lock. For Australia, Brazil, England, Europe and Japan, the flat head screws (8) have break-away heads and are not easily removable. To remove screws with break-away heads:
a. Use a center punch to make a pilot hole at the top of each screw.
b. Insert a 1/8-inch (3 mm) left-hand drill bit into a drill, and set the drill to "REVERSE".
c. Position the drill bit in the pilot hole, and power the drill at a slow speed to extract the screw. Repeat for the remaining screw. If the above method fails, use a 3/16-inch (5 mm) long shank drill bit to carefully drill off the heads of the break-away screws. Use a pliers to unthread the screw shafts from the fork lock.
5. Remove the Phillips pan head screw (9), nut (11) and flat washer (10) holding the front of the handlebar cover (2) to the nacelle. Discard the handlebar cover, but retain the screw, nut and washer.
1Clamp screw (4)
2Upper clamp
3Handlebar
4Handlebar riser (2)
5Riser attaching screw (2)
Figure 2. Handlebar Clamp and Risers (FLHR Models)
6. See Figure 2. Remove and discard the screws (1) that fasten the handlebar upper clamp (2) to the risers (4). Discard the clamp. Remove the handlebar (3) from the motorcycle.
NOTE
Make note of the installed sequence of the riser attaching hardware to aid correct assembly later in this installation.
7. Remove and discard the OE handlebar risers. Save the remaining hardware for later installation.
NOTE
DO NOT remove the wires from the Molex handlebar switch connector pin housings inside the nacelle.
8. Note the wire colors and positions in each cavity of the socket housings leading from the switches. Refer to the wiring diagram and the MOLEX ELECTRICAL CONNECTORS section in the service manual. Remove the wires (with socket terminals) from the socket housings.
9. Use tape to wrap the wire terminal ends from each source to make separate leaders. Wrap each leader tight enough to enter the grommet hole and pass easily through the new handlebar.
New Handlebar Wiring
1. Obtain three pieces of string, mechanic's wire or equivalent, each of sufficient length to extend inside the handlebar, from the end of the bar to the lower center wire slot, plus six to twelve inches (15-30 cm) of additional length to extend beyond the openings.
a. Tie a small weight (for example, a spare nut or washer small enough to fit through the center wire slot) to one end of each string.
b. Insert the weighted end of two of the strings into the right-side handlebar end, and tip the handlebar so that the weights and strings slide down the handlebar to the lower center wire slot. If necessary, an air hose can be used to blow the weights and strings through the handlebar to the center slot.
c. While ensuring that the non-weighted ends of the strings remain extended out of the right-side handlebar end, pull the weighted ends out of the lower center wire slot. Remove the weights from the strings.
d. With a tweezers or similar tool, fish one string out through the switch wiring slot near the right-side handlebar end. Allow the second string to remain extended out of the right-side handlebar end.
e. Repeat steps 1b through 1d with the one remaining string and the left-side handlebar end. Fish the string out through the switch wiring slot near the left-side handlebar end.
2. If not already done, remove the plastic wiring retainer clips that secured both handlebar switch harnesses to the original handlebar.
NOTE
Pay attention to the style and orientation of the grommets so they will install into the switch harness slots correctly when the wire harnesses have been pulled through.
3. See Figure 6. Slide the full flanged left-side grommet (2), flange end first onto the left-side switch-wire bundle, positioning the grommet close to the switch end. Slide the partial flanged right-side grommet (3), flange end first onto the right-side switch-wire bundle, positioning the grommet close to the switch end, with the flange oriented toward the center of the handlebar.
NOTE
DO NOT attempt to re-use the OE twist grip sensor with the new handlebar. The small green connector on the OE sensor is not compatible with internally wired handlebars. The OE sensor MUST be replaced with a new sensor (part number 32310-08), sold separately.
4. Obtain the Twist Grip Sensor Kit (purchased separately). Use tape to wrap the wire terminals on the ends of the twist grip sensor wires to make a single leader. Wrap the leader tight enough to pass easily through the new handlebar.
5. Tie the end of the string from the right-side handlebar end hole to the twist grip sensor wire bundle.
6. Tie the end of the string from the right-side switch wire hole to the right-side switch wire bundle.
7. Apply a light coat of liquid soap, window cleaner, or all-purpose lubricant to the right-side switch and twist grip sensor wire bundles.
WARNING
Wiring in the switch housings must be routed exactly as shown. Pinch points in the switch housings can short-circuit or sever wires, which could cause loss of control resulting in death or serious injury. (00415b)
8. Gently feed the twist grip sensor wire bundle into the right-side handlebar end. See Figure 3. Route the right-side switch wire bundle through the switch housing as shown. Gently feed the wire bundle into the right-side switch wire hole. Pull the bundles down through the new handlebar and toward the center of the bar, while fitting the index tabs on the twist grip sensor into the slots on the end of the handlebar. One index tab and slot are smaller than the other to prevent improper assembly.
1Upper switch housing screw
2Lower switch housing screw
3Pinch points
Figure 3. Switch-Housing Wire Routing (Right-Side Housing Shown)
WARNING
Carefully pull the wires through hole in handlebar to prevent stripping the wires. Stripped wires can cause short circuits and damage vehicle electrical components, which could cause loss of vehicle control resulting in death or serious injury. (00418b)
9. Pull the taped ends of the wire bundles through the wire-exit hole at the bottom center of the handlebar.
WARNING
Grommets in each of the wiring holes in the handlebar must remain in position after routing the wiring through the handlebar. Operation without the grommets in place can damage wires, causing a short circuit which could result in death or serious injury. (00416d)
10. Tie the end of the string from the left-side switch wire hole to the left-side switch wire bundle.
11. If necessary, apply a light coat of liquid soap, window cleaner, or all-purpose lubricant to the left-side switch wire bundle.
12. Route the left-side switch wire bundle through the switch housing similar to that shown in Figure 3 for the right-side wiring. Gently feed the wire bundle into the left-side switch wire hole. Pull the bundle down through the new handlebar and toward the center of the bar.
NOTE
Insert the right-side grommet into the handlebar slot with the flange toward the center of the bar.
13. See Figure 6. Insert the switch-wire grommets (2 and 3) into place in the switch-wire holes in the handlebar.
14. Loosely fasten the brake-lever and clutch-lever clamps to the new handlebar.
15. Loosely fasten the handlebar switch housings to the new handlebar.
16. See Figure 6 :
a. Cut the 4 in. (102 mm) long piece of heat-shrink tubing (4) from the kit into two equal pieces.
b. Slide one piece of the tubing over the end of each switch-wire bundle exiting the center hole of the handlebar.
17. Remove the tape from the ends of the wire bundles.
18. Check for electrical continuity between the handlebar and each wire in the wire bundles. Continuity would indicate a short circuit, which would require examination of the wires and routing in the switch housing.
NOTE
The heat-shrink tubing on the wire bundles exiting the bottom center of the handlebar must be installed to protect the wires from damage and short circuits at the wire-exit hole on the handlebar.
WARNING
Wires exiting the bottom center of the handlebar must be protected from wear with heat-shrink tubing at the wire-exit hole on the handlebar. Failure to protect wires with shrink tubing can cause short-circuits or severed wires, which could cause loss of vehicle control resulting in death or serious injury. (00432c)
19. Position the heat-shrink tubing (installed on the wire bundles in step 16) in the area of the center wire-exit hole on the handlebar.
WARNING
Be sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a)
  • Avoid directing heat toward any fuel system component. Extreme heat can cause fuel ignition/explosion resulting in death or serious injury.
  • Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed.
  • Always keep hands away from tool tip area and heat shrink attachment.
  1. Use a heat gun or suitable radiant-heating device to shrink the heat-shrink tubing to the wire bundles. Proceed to "New Handlebar Installation".
New Handlebar Installation
1. Obtain a Handlebar Riser Kit (E), purchased separately. See Figure 4. Position each riser with the mounting hole (8) outboard as shown. Install the new risers onto the upper fork bracket using the saved hardware in the same sequence as removed. Snug the riser bolts, but do not fully tighten at this time.
1Snug left rear screw
2Snug right front screw
3Tighten left front screw
4Tighten right rear screw
5Tighten left rear screw
6Tighten right front screw
7Front of vehicle
8Riser mounting holes to outside
9Handlebar
10Upper clamp lobes to outside
Figure 4. Handlebar and Clamp Assembly to Risers
2. Center the new handlebar (9) on the risers. To make sure that the handlebar is centered, verify that the knurled handlebar areas exposed on the outboard side of each riser are equal.
3. Position the new handlebar upper clamps (included in the Handlebar Riser Kit) with the rounded "lobes" (10) outboard, as shown, and loosely install with new clamp screws and flat washers from the kit.
NOTE
The handlebar upper clamps are machined to leave a gap between the clamp and riser on one side of the handlebar when installed. The non-gap side will be to the rear of the handlebar on the left clamp and to the front on the right clamp when the lobes are oriented outward.
4. Snug the upper clamp screws, but do not fully tighten, in the following sequence:
a. Snug only the rear screw (1) on the left-side clamp.
b. Snug only the front screw (2) on the right-side clamp.
5. Refer to the notes made during the removal steps, and the wiring diagram and MOLEX ELECTRICAL CONNECTORS section in the service manual. Insert each socket terminal from the left-side switch-wire bundle into the correct cavity of the gray socket housing removed earlier.
6. Insert each socket terminal from the right-side switch-wire bundle into the correct cavity of the black socket housing removed earlier.
7. Connect the gray socket housing to the gray eight-way pin housing inside the nacelle. Connect the black socket housing to the black six-way pin housing inside the nacelle. If so equipped, connect the three-way cruise control pin and socket housings in the same manner.
8. Obtain the PVC tubing from the Twist Grip Sensor Kit (purchased separately). Install the tubing over ALL of the wires coming from the twist grip sensor.
9. Obtain the six-way black Molex pin housing from the Twist Grip Sensor Kit (purchased separately). Insert each pin terminal from the twist grip sensor into the correct cavity of the pin housing as follows: From the yellow conduit, From the black conduit,
a. BLACK wire to cavity 1
b. WHITE wire to cavity 2
c. RED wire to cavity 3
d. BLACK wire to cavity 4
e. WHITE wire to cavity 5
f. RED wire to cavity 6
10. Connect the six-way black Molex pin housing from the twist grip sensor to the black six-way socket housing inside the nacelle. Position the PVC tubing installed in step 8 to prevent chafing of the twist grip sensor wires inside the nacelle.
NOTE
For vehicles equipped with heated grips, the Twist Grip Sensor Kit includes the necessary pin and socket housings, locks, seals and other items needed to connect the grips to the twist grip sensor. Refer to the instructions included with the heated grips for proper installation.
See Table 3 for components of the Twist Grip Sensor Kit.
NOTICE
Improperly aligned handlebars or components can contact the fuel tank when turned to the left or right. Contact with the fuel tank can cause cosmetic damage. (00372b)
11. Slowly turn the front wheel to the full right fork stop and then the full left fork stop to be sure the handlebar does not contact the fuel tank. If contact occurs and the handlebars are properly centered, raise the handlebar angle as necessary until proper clearance is attained.
NOTE
The upper handlebar-clamp screws MUST be final-tightened in the following sequence to be sure proper clamping is achieved.
12. See Figure 4. Tighten the upper handlebar-clamp screws as follows:
a. Tighten the left-side rear screw (1) until the left-side handlebar clamp makes contact with the rear of the handlebar riser.
b. Tighten the right-side front screw (2) until the right-side handlebar clamp makes contact with the front of the handlebar riser.
c. Tighten the left-side front screw (3) to 16.3–21.7 N·m (12–16 ft-lbs).
d. Tighten the right-side rear screw (4) to 16.3–21.7 N·m (12–16 ft-lbs).
e. Tighten the left-side rear screw (5) to 16.3–21.7 N·m (12–16 ft-lbs).
f. Tighten the right-side front screw (6) to 16.3–21.7 N·m (12–16 ft-lbs).
NOTE
There will be a slight gap between the upper clamps and the risers toward the left front and right rear of the handlebar after tightening.
13. Remove only ONE of the riser bolts installed in step 1. Apply two drops of Loctite® 271 (Red) to the bolt threads and install the bolt. Tighten the riser bolt to 41–54 N·m (30–40 ft-lbs). Repeat, one at a time, with the remaining three bolts.
14. Install a new (purchased separately) or original handlebar grip on the left end of the new handlebar according to the handlebar grip instruction sheet or the OE handlebar grip instructions in the service manual.
15. Adjust the positions of the switch housing and the clutch lever assembly on the handlebar for rider comfort.
16. Use a T27 TORX drive head to tighten first the top, then the bottom clutch-lever clamp screws to 8.1–12.2 N·m (72–108 in-lbs).
17. Use a T25 TORX drive head to tighten first the lower, then the upper switch housing screws to 4–5.1 N·m (35–45 in-lbs).
NOTE
If the handlebar grips are patterned, align the pattern on the right grip with the pattern on the left grip while the throttle is in the fully closed position.
18. Refer to the service manual, and follow the instructions given to install the new (purchased separately) or original right grip/throttle sleeve.
19. Adjust the position of the switch housing and the brake lever assembly on the handlebar for rider comfort. The brake master cylinder must be horizontally level.
NOTE
Tighten the top brake lever clamp screw before tightening the bottom screw.
20. Use a T27 TORX drive head to tighten first the top, then the bottom brake-lever clamp screws to 8.1–12.2 N·m (72–108 in-lbs).
NOTE
Tighten the lower switch housing screw before tightening the upper screw. This will leave any gap in the switch housing at the front for best appearance.
21. Use a T25 TORX drive head to tighten first the lower, then the upper switch housing screws to 4–5.1 N·m (35–45 in-lbs).
22. Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing.
Final Assembly
1. To avoid possible damage to the brake hose, verify that the trim strips remain installed on the inside edges of the headlamp nacelle. Replace the strips if missing, cracked or broken.
2. See Figure 5. Loosen the two acorn nuts securing the left half of the nacelle (see arrows). Repeat for the right half of the nacelle.
Figure 5. Headlamp Nacelle Fasteners (FLHR Models)
3. See Figure 6. For North America: Obtain a new handlebar clamp cover (D, sold separately), and the two flat head Phillips screws (B, saved earlier). For Australia, Brazil, England, Europe and Japan: Obtain a new handlebar clamp cover (D, sold separately), and two new screws (B, part number 2935A, purchased separately).
4. See Figure 6. Position the cover onto the flange at the top of the headlamp nacelle. Install the two screws (B) to secure the handlebar clamp cover to the fork lock mechanism. For North America: Tighten the flat head Phillips screws to 1.1–2.3 N·m (10–20 in-lbs). For Australia, Brazil, England, Europe and Japan: Tighten the special T-27 TORX® screws until the break-away heads snap off.
5. Press the original fork-lock label plate (A) into position on the handlebar cover.
6. Obtain the pan head Phillips screw, nut and flat washer removed earlier. Insert the screw (C) through the hole at the front of the handlebar cover and the top of the headlamp nacelle. Reach inside the nacelle and install the nut and flat washer onto the screw threads. Tighten the screw to 1.1–2.3 N·m (10–20 in-lbs).
7. Obtain the nacelle trim strip and serrated flange nut removed earlier. Insert the hook on the trim strip into the slot on the handlebar cover. Insert the weld stud on the trim strip into the hole at the top of the headlamp nacelle, and reach inside the nacelle to install the flange nut. Tighten the nut to 1.7–2.3 N·m (15–20 in-lbs).
8. Install the headlight into the nacelle. See the service manual.
9. See Figure 5. Tighten the two acorn nuts securing the left half of the nacelle to 8.1–12.2 N·m (72–108 in-lbs). Repeat for the right half of the nacelle.
WARNING
Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a)
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly. (00321a)
  1. Carefully inspect the new brake line or lines (sold separately) for damage or defects, and replace if damaged. Install per the instructions included with the brake lines.
  2. Bleed the brakes. See the service manual.
  3. Re-install the clutch cable to the clutch lever or install a new clutch cable (sold separately) per the instructions in the service manual.
SAFETY CHECK
WARNING
Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a)
  • Be sure wires, clutch cables and brake lines do not pull tight when handlebars are turned fully to left or right fork stops.
WARNING
Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)
1. Verify that the Ignition/Light Key Switch is turned to the OFF position. Apply a light coat of petroleum jelly or corrosion retardant material to the battery terminals. Refer to the service manual and follow the instructions given to attach the battery cables (positive cable first).
WARNING
Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)
2. Turn the Ignition/Light Key Switch to IGNITION, but do not start the motorcycle. Test each handlebar switch for proper operation.
3. Turn the handlebar to the left and right steering stops, testing the handlebar control functions at each stop.
4. Apply the front brake hand lever to test operation of the brake lamp.
5. Refer to the service manual, and follow instructions to install the seat.
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
WARNING
Before starting engine, be sure throttle control will snap back to idle position when released. A throttle control that prevents engine from automatically returning to idle can lead to loss of control, which could result in death or serious injury. (00390a)
WARNING
After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a)
SERVICE PARTS
Figure 6. Service Parts, Handlebar Kit
Table 1. Service Parts, Handlebar Kit
Item
Description (Quantity)
Part Number
1
Handlebar
Not sold separately
2
Handlebar grommet, left side (with full flange)
11403A
3
Handlebar grommet, right side (with partial flange)
11642
4
Heat-shrink tube
72162-02
Items mentioned in text, but not included in Handlebar Kit:
A
Original equipment fork-lock plate
B
Original equipment Phillips flat head screws (2, for North America)
Break-away flat head TORX screws (2, for Australia, Brazil, England, Europe and Japan)
2933
2935A
C
Original equipment Phillips pan head screw
D
Handlebar cover (purchase separately.)
67893-02
Table 2. Service Parts, Handlebar Riser Kit
Item
Description (Quantity)
Part Number
E
Handlebar riser kit (includes Items F through I)
56789-05
F
  • Handlebar riser (2)
Not sold separately
G
  • Handlebar upper clamp (2)
Not sold separately
H
  • Upper handlebar clamp screw (4)
4816A
I
  • Flat washer (4)
6046
Table 3. Service Parts, Twist Grip Sensor Kit (Part Number 32310-08)
Item
Description (Quantity)
Part Number
Items for Twist Grip Sensor:
1
Sensor, twist grip (for internally-wired handlebars)
Not sold separately
2
Pin housing, six-way
72188-07BK
3
Retainer, T-stud
73212-07
4
Cable strap
10006
5
PVC tubing
Not sold separately
Items used with Heated Hand Grips only:
6
Socket housing, two-way
72112-94BK
7
Secondary lock, two-way socket housing
72152-94
8
Seal pin (plug) (2)
72195-94
9
Pin housing, two-way
72102-94BK
10
Secondary lock, two-way pin housing
72142-94